Method and Appartus for Making Retarder in Stereoscopic Glasses

ABSTRACT

A 3-D stereoscopic viewing lens which the retarder film is made of a PVA film. A 3-D stereoscopic viewing lens having a linear polarized film, one or more lens substrate layers, and an epoxy layer. A process of making retarder film including mounting a PVA film to an assembly line; wetting, cleaning, and washing the PVA film through said assembly line; softening, expanding and stretching the PVA film&#39;s x-axis through said assembly line; adding gap filling agent to the PVA film; stretching the PVA film&#39;s y-axis through a width frame holder and as a result transforming the PVA film into a retarder film.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. provisional application Ser.No. 61/302,553 filed on Feb. 9, 2010, U.S. provisional application Ser.No. 61/313,598 filed on Mar. 12, 2010, U.S. provisional application Ser.No. 61/313,598 filed on Apr. 23, 2010, U.S. provisional application Ser.No. 61/334,856 filed on May 14, 2010, the disclosures of which areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention entails a novel process of forming a curved lensfor improved 3-D perception of stereoscopic motion pictures, whereby thecurved lens shape is formed involving a continuous stretch process ofmaking the retarder film to prevent distortion and defects due toforming the retarder in curved form. The novel method allows for thinnerstretching of PVA (organic polyvinyl alcohol) and polymer to perfect thecurve shape for better matching between the lens and the user's eyes.Other improvements include the ability for retarder optical device to belaminated to the linear or circular polarizer without need for an extrapolymer sheet, thereby improving light transmission for 3-D stereoscopicviewing, and for production of various specific thicknesses of theretarder film to enhance viewing contrast.

BACKGROUND OF THE INVENTION

Stereoscopy, or three dimensional imaging, relates to any technique thatrecords three dimensional visual information and creates an illusion ofenhanced depth in a user's perceived image. Traditional two dimensionalimages utilize human visual cues of occlusion of one object by another,convergence of parallel edges, change in size of textured patterns,haze, desaturation, shift to bluishness, and subtended visual angle.Stereoscopy enhances the illusion of depth in motion pictures,photographs, and other two dimensional images by presenting slightlydifferent images to each eye, and thereby adding the human visual cue ofstereopsis.

Glasses for viewing three dimensional images exist in two categories:active and passive. Among active 3-D glasses are liquid crystal shutterglasses and display glasses. Liquid crystal shutter glasses containliquid crystal that blocks or passes light through synchronization withimages on a computer display, using alternate frame sequencing.Stereoscopic head-mounted displays include one display per eye, whichdisplay a different perspective near each eye, and are not used inconjunction with an external screen to be viewed at distance. Examplesof active 3-D glasses include Active shutter glasses lens controlled byinfrared (IR), radio frequency (RF), DLP-LINK®, BLUE-TOOTH® TRANSMITTERwhich use electronic component to receive signal from emitter connectedto display to activate a light shutter with the frequency of 120 Hertzor 240 Hertz or more.

Passive 3-D glasses include linearly-polarized glasses,circularly-polarized glasses, infitec glasses, complementary coloranalyphs, chromadepth method glasses, anachrome compatible color analyphglasses, and red-eye shutter glasses where the most prevalent would belinearly-polarized glasses and circularly-polarized glasses. Linearlypolarized glasses are used when a stereoscopic motion picture isprojected and superimposed on the same screen through orthogonalpolarizing filters. The viewer wears glasses containing orthogonalpolarizing filters, which only pass through similarly polarized lightand block orthogonally polarized light, allowing the viewer to only seeone of the images in each eye to achieve a 3-D effect. Viewers must keeptheir heads level in order to prevent bleeding of images from the leftand right channels into the opposite channel.

Circularly polarized glasses are used in circumstances where two imagesare projected superimposed onto a screen through circular polarizingfilters of opposite handedness. The user wears eyeglasses which containa pair of circular polarizing filters mounted in reverse, whereby lightthat is left-circularly polarized is extinguished by the right-handedanalyzer and light that is right-circularly polarized is extinguished bythe left-handed analyzer. This allows the user to tilt his head whileviewing stereoscopic images and still maintain left and rightseparation.

Passive linear lenses exploit the wavelength difference between blue andred color lenses to create a 3-D effect. However, this method results ina perceived image that deviates from the actual color of the object.

Circularly polarized glasses have the advantage over linear polarizedglasses because viewers with circularly polarized glasses may tilt theirheads and look about without a disturbing loss of 3-D perception,whereas viewers using linear polarized glasses must keep their headsaligned within a narrow range of tilt for effective 3-D perception, orrisk seeing double or darkened images.

Passive circularly polarized lenses in the market currently use flatlenses, which do not match the user's eyeball curvature and cause eyefatigue and discomfort. In addition, 3D effects is distorted if theviewers tilts their head beyond a certain angle from direct viewing ofthe screen. Despite the apparent short falls of the flat lens design,current market continues to utilize flat lens approach becausedistortion would result from curving the flat lens after molding andcutting the lens to suit the eye curvature. Specifically, this is causedprimarily due to the fact that such method would rearrange the moleculesin the film and degrade visual clarity.

As for active 3-D technology, the active shutter glass lens needs to bein a dark room in order to realize better resolution and fullstereoscopic sensation. Some people like this but some will feeluncomfortable as well as their eyes and brain will get tired in a longerperiod time over than 2 hours. Moreover, although active shutter glasslens has high resolution, the flat shape of frame and heavier than usualweight cause increased eye strain, eye pressure, and induce nausea andheadache when wore over long periods of time. Further, due to the flatlens shape, such lenses do not match the natural curvature of the eye.Due to the flashing of stereoscopic images at 120 Hertz or more, ittends to cause greater eye discomfort without a lens curvature. Thus,this invention also aims to create curvature lens for active 3D glasses.

Taken as a whole, current construction of flat lens, both active andpassive, limits the frame shape and design. Even when we try to use flatsheet laminated to cut shape and with heating to bend; it reduces theresolution of viewing, and lead to discomfort in eyes and brain. Thus,the present invention solves the problem by continuously stretching thepolarized lens and forming the lens into curved shape.

Further, a retarder is an optical device that alters the polarizationstate of a light wave traveling through it. The new method of processingthe retarder with new laminate technology improves the 3-D stereoscopicimage. The linear polarized film or partially circular polarized film isglued to the retarder inside the retarder include gap filling agent. Theepoxy liquid is laminated outside the retarder then cured with air or UVlight to create a “3-D circular polarized function card”. The newfunction card will have a better birefrigent effect without extrapolymer sheets, thus improving transmission. Currently state of the artallows for 60-85% transmission. Also current market uses polymer sheetsto support the linear polarizer. The use of polymer sheet requires moistglue, which interferes with transmission. This support must be assembledusing half-dry glue on the lens, which negatively affects lens clarity.Dry glue cannot be used in this assembly due to the limiting nature ofthe thick polymer retarder and linear polarizer.

In our invention, the thinness of the retarder and PVA film (polarizer)allows the application of almost crystallized lamination possible.Specifically, the present invention solves this problem through aprocess by which a thin retarder and PVA or circular polarizer may beproduced and assembled with dry glue. This process allows the wearer toview stereoscopic images for a longer time period without discomfort.The process entails application of organic polyvinyl alcohol (PVA) orany selection among polymer polyurethane (PU), polyvinyl chloride (PVC),polypropylene (PP), polycarbonate (PC), or polyester (PE) as theingredient to create retarder film with linear or partially circularpolarization on different surfaces, such as flat and curved sheets, as asubstantial improvement to current flat 3-D lenses and to end userviewing comfort. Other advantages of these methods versus previousmethods include making distortion-free, thinner, flexible, functional,comparable, durable, optimal-performance circular polarized 3D lens.This innovative method allows for conformation of the lens shape onto aflat and curved surface when the lens is still malleable and moistrather than cutting the lens from a flat sheet of polymer.

OBJECT OF THE INVENTION

The purpose of present invention is to apply high quality retarder filmto create full color, and virtually high resolution passive circularpolarized 3D lens for aesthetical and comfortable eyewear to viewstereoscopic images. Other advantages of these method versus previousmethods include making distortion-free, thinner, flexible, functional,comparable, durable, optimal-performance circular polarized 3D lens.This innovative method allows production of forming lens shape into aflat and curved surface when the lens is still malleable and moistrather than cutting the lens from a flat sheet of polymer.

Objective of the present invention include production of high qualityretarder film and application of said film to passive circularlypolarized 3-D lenses in order to create aesthetically pleasing andhighly comfortable eyewear to view stereoscopic images in accurate andbrilliant color and full resolution.

Another objective of this invention is to produce distortion-free,thinner, more flexible and durable, and visually-optimizedcircularly-polarized 3-D lenses through the novel process of formingcurved lens surfaces during the malleable or moist lens productionphase, as opposed to cutting the lens from a flat polymer sheet, whichcauses optical distortion and end user discomfort.

SUMMARY OF THE INVENTION

One aspect of the invention includes a 3-D stereoscopic viewing lenscomprising a retarder film wherein the retarder film is comprised of aPVA film. In one embodiment, the 3-D stereoscopic viewing lens furthercomprising a linear polarized film, one or more lens substrate layers,an epoxy layer. In another embodiment, the 3-D stereoscopic viewing lensis has a shape of a curvature. In another embodiment, the 3-Dstereoscopic viewing lens further comprising a linear polarized film, aLCD layer, an ITO layer, a glass layer and a lens substrate layer Inanother embodiment, the retarder film is made comprising the followingsteps: mounting a PVA film to an assembly line; wetting, cleaning, andwashing the PVA film through the assembly line; softening, expanding andstretching the PVA film's x-axis through the assembly line; adding gapfilling agent to the PVA film; stretching the PVA film's y-axis througha width frame holder whereby transforming the PVA film into a retarderfilm. In another embodiment, the retarder film is made furthercomprising the following steps: mounting the retarder film onto amultiple holding frame; pressing a convex mold onto the retarder film toforce the retarder film into a desired curved shape through one or moreopenings of the multiple holding frame; heating the retarder film toreduce the retarder film's moisture content; drying the retarder film.

In yet another embodiment, water is used in the process of wetting,cleaning and washing. In another embodiment, the processing of wetting,cleaning and washing is continued until the PVA film reachesapproximately 70%-85% water saturation. In another embodiment, theprocessing of softening, expanding and stretching is carried out by oneor more rollers mounted in the assembly line. In another embodiment, thegap filling agent is comprised on of potassium iodide, sodium iodide,copper (I) iodide, boric acid, and sodium tetra borate decahedra. Inanother embodiment, the gap filling agent is added during the processingof softening, expanding and stretching the PVA film. In anotherembodiment, the gap filling agent is added during the processing ofsoftening, expanding and stretching the PVA film.

In another embodiment, the retarder film is stretched to about 3 to 6times its original size along its x-axis. In another embodiment, theretarder film's width is reduced to about one half of its originalwidth. In another embodiment, the retarder film's thickness is reducedto 0.02-0.12 mm thick.

In yet another embodiment, the retarder film is heated to about 60° C.to 80° C. wherein the process of heating is continued until the retarderfilm's moisture content is reduced to about 50%; In another embodiment,the process of drying takes place in a environment at approximately 25°C. and at 40-50% humidity until the retarder film's moisture content isreduced to about 40%.

In another aspect of the invention, method of making a 3-D stereoscopicviewing lens comprising the following steps: mounting a PVA film to anassembly line; wetting, cleaning, and washing the PVA film through theassembly line; softening, expanding and stretching the PVA film's x-axisthrough the assembly line; adding gap filling agent to the PVA film;stretching the PVA film's y-axis through a width frame holder wherebytransforming the PVA film into a retarder film; mounting the retarderfilm onto a multiple holding frame; pressing a convex mold onto theretarder film to force the retarder film into a desired curved shapethrough one or more openings of the multiple holding frame; heating theretarder film to reduce the retarder film's moisture content; drying theretarder film. In another embodiment, the method further includespreparing a concave mold and a convex mold; adding epoxy onto theconcave mold; affixing the retarder film onto the convex mold;positioning the retarder film with convex mold wherein the retarder filmwith convex mold is pressed down onto the epoxy with concave mold;compressing the convex mold with the concave mold; applying UV treatmentto the convex mold and the concave mold; opening the convex mold and theconcave mold; affixing a linear polarized film to the convex mold;adding UV glue to the retarder film; pressing the convex mold having thelinear polarized film to the concave mold having the retarder film withUV glue; applying UV dry treatment to the concave mold and the convexmold whereby the retarder film laminates with the linear polarized filmto form circular polarized film; removing the convex mold from theconcave mold; applying UV glue to the circular polarized film; affixinglens substrate to the convex mold; compress the convex mold having thelens substrate with the concave mold having the circular polarized filmto form a 3-D stereoscopic viewing lens; applying UV treatment to theconvex mold and the concave mold; remove the 3-D stereoscopic viewinglens from the convex mold and the concave mold. In another embodiment,the lens substrate is selected from a group consisting of AC, CR, PU,TAC, and GLASS.

In another aspect of the invention, a retarder for a 3-D stereoscopicviewing lens wherein the retarder film is comprised of a PVA film isdisclosed. In another embodiment, the retarder film is made comprisingthe following steps: mounting a PVA film to an assembly line; wetting,cleaning, and washing the PVA film through the assembly line; softening,expanding and stretching the PVA film's x-axis through the assemblyline; adding gap filling agent to the PVA film; stretching the PVAfilm's y-axis through a width frame holder whereby transforming the PVAfilm into a retarder film; mounting the retarder film onto a multipleholding frame; pressing a convex mold onto the retarder film to forcethe retarder film into a desired curved shape through one or moreopenings of the multiple holding frame; heating the retarder film toreduce the retarder film's moisture content; drying the retarder film.

In another aspect of the invention, a 3-D stereoscopic viewing lenscomprising a retarder film wherein the retarder film is comprised of apolymer film selected from a group consisting of PU, PVC, PP, PC, NYLON,PE, CAB, CP, DAC and TAC film is disclosed. In another embodiment, theretarder film is made comprising the following steps: keeping a polymerfilm in a proper temperature at over 90° C.-120° C. until the polymer ismalleable; mounting the polymer film to an assembly line; softening,expanding and stretching the polymer film's x-axis through the assemblyline; stretching the polymer film's y-axis through a width frame holderwhereby transforming the polymer film into a retarder film.

In yet another aspect of the invention, a 3-D stereoscopic viewing lenscomprising the following steps is disclosed: providing polymer filmselected from a group consisting of PU, PVC, PP, PC, NYLON, PE, CAB, CP,DAC and TAC film; keeping the polymer film in a proper temperature atover 90° C.-120° C. until the polymer is malleable; mounting the polymerfilm to an assembly line; softening, expanding and stretching thepolymer film's x-axis through the assembly line; stretching the polymerfilm's y-axis through a width frame holder whereby transforming thepolymer film into a retarder film; mount the retarder film onto amultiple holding frame; pressing a convex mold onto the polymer film toforce the retarder film into a desired curved shape through one or moreopenings of the multiple holding frame; preparing a concave mold and aconvex mold; adding epoxy onto the concave mold; affixing the retarderfilm onto the convex mold; positioning the retarder film with convexmold wherein the retarder film with convex mold is pressed down onto theepoxy with concave mold; compressing the convex mold with the concavemold; applying UV treatment to the convex mold and the concave mold;opening the convex mold and the concave mold; affixing a linearpolarized film to the convex mold; adding UV glue to the retarder film;pressing the convex mold having the linear polarized film to the concavemold having the polymer film with UV glue; applying UV dry treatment tothe concave mold and the convex mold whereby the retarder film laminateswith the linear polarized film to form a circular polarized film;removing the convex mold from the concave mold; applying UV glue to thecircular polarized film; affixing lens substrate to the convex mold;compress the convex mold having the lens substrate with the concave moldhaving the circular polarized film to form a 3-D stereoscopic viewinglens; applying UV treatment to the convex mold and the concave mold;removing the 3-D stereoscopic viewing lens from the convex mold and theconcave mold.

In yet another aspect of the invention, the making of a 3-D stereoscopicview lens further includes the following steps: preparing a concave moldand a convex mold; adding liquid glass onto the concave mold to form aglass substrate layer; apply glue to the glass substrate layer; affixingthe retarder film onto the convex mold; positioning the retarder filmwith convex mold wherein the retarder film with convex mold is presseddown onto the glass substrate layer with concave mold; compressing theconvex mold with the concave mold; applying UV treatment to the convexmold and the concave mold; opening the convex mold and the concave mold;affixing a linear polarized film to the convex mold; adding UV glue tothe retarder film; pressing the convex mold having the linear polarizedfilm to the concave mold having the retarder film with UV glue; applyingUV dry treatment to the concave mold and the convex mold whereby theretarder film laminates with the linear polarized film to form circularpolarized film; removing the convex mold from the concave mold; applyingUV glue to the circular polarized film; affixing lens substrate to theconvex mold; compress the convex mold having the lens substrate with theconcave mold having the circular polarized film to form a 3-Dstereoscopic viewing lens; applying UV treatment to the convex mold andthe concave mold; remove the 3-D stereoscopic viewing lens from theconvex mold and the concave mold.

In yet another aspect of the invention, the making of a 3-D stereoscopicview lens further includes the following steps: adding a glass substratelayer to a concave mold; vacuum coating the glass substrate layer withan ITO layer; adding a LCD layer to the ITO layer; affixing s lenssubstrate layer to a convex mold; adjoin the lens substrate layer withthe retarder film; compressing the convex mold with the concave moldwhereby the retarder film adjoins with the LCD layer to form a 3-Dstereoscopic viewing lens; applying UV treatment; removing the convexmold from the concave mold.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an embodiment of stretching of the retarder film;

FIG. 2 depicts an embodiment of the adjustable width holding frame;

FIG. 3 depicts an embodiment of an adjustable holding frame;

FIG. 4A depicts an embodiment of the multiple frame holder;

FIG. 4B depicts an embodiment of the multiple frame holder;

FIG. 5A depicts an embodiment of a 3-D lens;

FIG. 5B depicts an embodiment of a 3-D lens;

FIG. 6 depicts an embodiment of how a retarder film is aligned against alinear polarized film;

FIG. 7A depicts an embodiment of a 3-D lens;

FIG. 7B depicts an embodiment of a 3-D lens;

FIG. 8 depicts variations of how a retarder film is aligned against alinear polarized film;

FIG. 9A depicts an embodiment of a 3-D lens;

FIG. 9B depicts an embodiment of a 3-D lens;

FIG. 10 depicts an embodiment of a 3-D lens;

FIG. 11 depicts another embodiment of stretching of the retarder film;

FIG. 12 depicts an embodiment of the adjustable width holding frame;

FIG. 13 depicts an embodiment of an adjustable holding frame;

FIG. 14A depicts an embodiment of the multiple frame holder;

FIG. 14B depicts an embodiment of the multiple frame holder;

DETAILED DESCRIPTION OF THE EMBODIMENTS

The present invention discloses the making of the retarder film usingthe continuous stretching process to conform to the lens shape. It canreduce the distortion and defect of forming the retarder film.Specifically, the present invention provides method where it can stretchPVA (using a wetting process), and form it into curve shape and tobecome a retarder. The thinness of the film, using a wetting process,and proper temperature of polymer makes the polymer fit the shape ofmold in perfect match. That is excellent for retarder to form most shapeand curve. The new invention can apply to 3-D glasses, advertisementpanel, tail light, lamp, especially curved shape.

In addition, gap filling agent was added to the water tank in theassembly line process to fill almost all the gaps of molecule in PVAfilm to create a birefrigent film, flat or any shape of retarder film.While the curved lens has better 3D effect than flat lens, the newinvention further provides method for improving the effect of flat lensbecause the molecules of PVA or polymer (PU, PVC, PP, PC, NYLON, PE,CAB, CP, DAC and TAC film) are arranged in order.

New method to process retarder with new laminate technology improves the3D stereoscopic image. The linear polarized film is glued to theretarder film wherein inside the retarder film has inclusion of gapfilling agent. The epoxy liquid was laminated to the outside of theretarder film then cured with air or UV light to create an effective“3-D CIRCULAR POLARIZED FUNCTION CARD”. The new function card will havebetter birefrigent effect without extra polymer sheet, thus improve thetransmission. Other invention includes wherein the past, the use ofmultiple polymer sheets to support linear polarizer requires the use ofmoist glue for the polymer sheet to be glued to the linear polarizer.The moisture of the glue often interferes with transmission of light. Inthe present invention, because the thinness of the PVA film, it makesthe application of lamination of PVA film with linear polarizer possiblefor crystallized lamination.

Present invention can reduce the use of either the retarder, linearpolarized film materials to half of what the market is currentlycommanding, primarily due to the use of the application of epoxy to formsupport.

The following description is not to be taken in a limiting sense, but ismade merely for the purpose of describing the general principles of theinvention. The steps described herein for performing methods form oneembodiment of the invention, and, unless otherwise indicated, not all ofthe steps must necessarily be performed to practice the invention, normust the steps necessarily be performed in the order listed. The presentinvention is a retarder film and a method of making retarder. The majorsteps in producing the retarder and a 3-D stereoscopic viewing lens aredescribed in the following sections.

Example One I. Preparation of PVA Film for Use to Form Retarder Film

FIG. 1 depicts one embodiment of an assembly line to prepare a retarderfilm. Specifically, FIG. 1 depicts the process of continuous stretch ofthe PVA film along its X-axis. Starting with an untreated roll of PVAfilm, without directional molecular arrangement. Using rollers tostretch and transport PVA film from one or more stages as follows:

-   -   a. mount an untreated roll of PVA film 101 at the beginning of        assembly line 105;    -   b. use water to in processing tank 104 to wet, clean, and wash        the film 101 until it has approximately 70%-85% water        saturation;    -   c. softening, expanding and stretching the film as the film 101        continues to be stretched through roller 102, roller 103 and        roller 106.

In the stretching process gap filling agent (mixture of potassiumiodide, sodium iodide, copper (I) iodide, boric acid, and sodium tetraborate decahedra) was added to the processing tank 104 to form animproved PVA film. The addition of the gap filling agent is used to fillthe pores of the molecules to have birefringent effect. PVA film isstretched to about 3 to 6 times its original size along the x-axis,combining stretch, its width is reduced to about one half of itsoriginal widths, and its thickness is reduced to 0.12-0.02 mm thick. Themolecules of the PVA film will become more evenly aligned.

II. Forming the Retarder Film of Example One and Forming it into theDesired Curved Shape Using a Convex Mold

FIG. 2 and FIG. 3 depict one embodiment of a manual and semi-automaticor automatic adjustable clamping frame used for the next step oftransforming the PVA film into a retarder film. Specifically, aftersteps performed in FIG. 1, FIG. 2 depicts one embodiment of awidth-adjustable holding frame 208 to hold the PVA film along the Y-axis209 using a top and bottom clamping frames together with hinges 207;FIG. 3 depicts one embodiment of an adjustable holding frame 308stretched along the Y-axis 209 to a preset lockable position 311 whereinthe extension rod 310 locks it in place. Specifically, the PVA film isstretched here along the Y axis until the PVA film is 0.05 mm-0.01 mm inthickness. The PVA film, once stretched in its X-axis and its Y-axis, itbecomes a functional retarder film. The retarder film, remaining inproper temperature and moisture during the processing phase, isstabilized between lower frame plate and upper frame, which are heldtogether with frame hinges 207. Additional clips can be used to helpprevent retarder film from shrinking during shaping.

FIG. 4A depicts one embodiment of the retarder film 401 being formedinto a multiple holding frame 408 to form into a curved or flat or anydesired shape comprising the steps of:

-   a. stabilize and place retarder film 401 onto the multiple holding    frames 408 using multiple holding frame hinges 412;-   b. next press a convex mold 424 (FIG. 4B) onto retarder film 415    (FIG. 4B) to force the retarder film 412 (FIG. 4B) into the desired    curved shape through the oval openings 413 (FIG. 4A) of multiple    frame holder 414 (FIG. 4B);-   c. heat the retarder film at 60° C. to 80° C. until its moisture    content is about 50%;-   d. inspect and mark the molecule direction of the retarder film 415    (FIG. 4B); and-   e. dry the retarder film 415 (FIG. 4B) at approximately 25° C. and    40-50% humidity until its moisture content is about 40%.

Next, (referring back to FIG. 4A) retarder film is cut and removed fromthe multiple holding frame 408. As described earlier, multiple holdingframe 408 has an opening 413 in the center, which allows convex mold tobe pushed through multiple holding frame 408 and against the retarderfilm 401. One side of convex mold is used to shape the retarder film401. The convex surface of convex mold is pushed into the flat piece ofsoft retarder film to bend it into the desired shape, curve or arc.

Since retarder film is soft and wet, it will conform to its shape to themold. In one embodiment, convex mold is made of glass, such as glass incommon practice for forming thermosetting resin ophthalmic lenses, oranother material that is relatively transparent or semi-transparentpolymer, so that the epoxy can be cured by UV light which passes throughthe mold. In other embodiments, convex mold is made of a material whichconducts heat, so that heat can pass through the mold. Once arc isformed, retarder film is next heated at about 80° C. or less to removethe moisture in the retarder film without melting it. This should takeabout 10 minutes. Retarder film is relatively soft because it was “wet”due to its moisture content made, and once it becomes “dry” due to thereduction in moisture content, it will fix or lock in its shape. It isnoted that temperatures above 80° C. may melt or liquefy the retarderfilm.

Next, retarder film is inspected in a quality control stage after theinitial drying for air bubbles, dirt, color evenness, tears, etc. Thedioptre and other optical properties of the retarder film can bemeasured. If all is approved, the lens is marked with a moleculedirection. After marking, the retarder film can then be removed to aclean room at room temperature and low humidity levels for furthercooling. This produces a curved, dry retarder film that adheres betterto epoxy, which eventually becomes part of the 3-D stereoscopic viewinglens.

Example Two III. Preparation of Polymer Film for Use to Form RetarderFilm

FIG. 11 depicts one embodiment of an assembly line to prepare a retarderfilm. Polymer film can be polymer Polyurethane (PU), Polyvinyl chloride(PVC),Polypropylene (PP), Polycarbonate (PC), Polyester (PE), (CAB)Cellulose Acetate Butyrate, (CP) Cellulose Acetate Propionate, (DAC)Cellulose Diacetate and (TAC) Triacetate Cellulose film. Specifically,FIG. 11 depicts the process of continuous stretch of the polymer filmalong the X-axis. Starting with an untreated roll of polymer film,without directional molecular arrangement. Using rollers to stretch andtransport polymer film from one or more stages as follows:

-   -   d. mount an untreated roll of polymer film 1101 at the beginning        of assembly line 1105;    -   e. heat the polymer film to temperature over 90° C.-120° C.        wherein said film becomes malleable;    -   f. stretching the film as the film 1101 continues to be        stretched through roller 1102, roller 1103 and roller 1106.

Polymer film is stretched to about 3 to 6 times its original size alongthe x-axis, combining stretch, its width is reduced to about one half ofits original widths, and its thickness is reduced to 0.12-0.02 mm thick.The molecules of the polymer film will become more evenly aligned.

IV. Forming the Retarder Film of Example Two and Forming it into theDesired Curved Shape Using a Convex Mold

FIG. 12 and FIG. 13 depict one embodiment of a manual and semi-automaticor automatic adjustable clamping frame used for the next step oftransforming the polymer film into a retarder film. Specifically, aftersteps performed in FIG. 11, FIG. 12 depicts one embodiment of awidth-adjustable holding frame 1208 to hold the polymer film along theY-axis 1209 using a top and bottom clamping frames together with hinges1207; FIG. 3 depicts one embodiment of an adjustable holding frame 1308stretched along the Y-axis 1209 to a preset lockable position 1311wherein the extension rod 1310 locks it in place. Specifically, thepolymer film is stretched here along the Y axis until the PVA film is0.05 mm-0.01 mm in thickness. The polymer film, once stretched in itsX-axis and its Y-axis, it becomes a functional retarder film. Afterstretching is done, use the spectrum measure machine and reflectionindex data to adjust the stretch machine to what is desired.

The retarder film, remaining in proper temperature during the processingphase, is stabilized between lower frame plate and upper frame, whichare held together with frame hinges 1207. Additional clips can be usedto help prevent retarder film from shrinking during shaping.

FIG. 14A depicts one embodiment of the retarder film 1401 being formedinto a multiple holding frame 1408 to form into a curved or flat or anydesired shape comprising the steps of:

-   f. stabilize and place retarder film 1401 onto the multiple holding    frames 1408 using multiple holding frame hinges 1412;-   g. next press a convex mold 1424 (FIG. 14B) onto retarder film 1415    (FIG. 14B) to force the retarder film 1415 (FIG. 14B) into the    desired curved shape through the oval openings 1413 (FIG. 14A) of    multiple frame holder 1414 (FIG. 14B);-   h. inspect and mark the molecule direction of the retarder film 1415    (FIG. 14B); and

Next, (referring back to FIG. 14A) retarder film is cut and removed fromthe multiple holding frame 1408. As described earlier, multiple holdingframe 1408 has an opening 1413 in the center, which allows convex moldto be pushed through multiple holding frame 1408 and against theretarder film 1401. One side of convex mold is used to shape theretarder film 1401. The convex surface of convex mold is pushed into theflat piece of soft retarder film to bend it into the desired shape,curve or arc.

V. Addition of Hard Epoxy to the Outer, Convex Side of the Retarder Filmof Example One and Example Two

FIG. 5A depicts one embodiment of an overview of a 3-D stereoscopicviewing lens comprising a convex mold 521, a concave mold 518 holdingepoxy layer 517, retarder film 516, linear polarized film 515 and lenssubstrate 514. Depicted in FIG. 5B (from the left column down and up andthrough the right column), the steps are as follows:

-   -   a. polish and clean the surface of concave mold 518;    -   b. add about 5 cc of hard epoxy 517 in liquid form onto concave        mold 518; and    -   c. position concave mold 518 and convex mold 521 together so        that the outer surface of retarder film 516 is pressed down onto        epoxy liquid 517;    -   d. compress molds together;    -   e. apply UV treatment 520;    -   f. apply linear polarized film 515 on the convex mold 518;    -   g. add UV glue 519 on the top of the retarder film 516;    -   h. press convex mold 521 having linear polarized film 515 on to        the UV glue 519    -   i. adding UV dry treatment 520;    -   j. here a “3-D circular polarized function card” is formed;    -   k. add UV glue 519 on top of polarized function card;    -   l. affixing lens substrate comprised of AC, CR, PU, TAC, or        GLASS materials 514 on to convex mold;    -   m. compress molds together; when laminating the retarder 516 and        linear polarized 519, paying careful attention that the angle is        correct at +45 degrees and −45 degrees as disclosed in FIG. 6        where the retarder 622 is positioned against linear polarized        film 623 at a −45 degree and at a −45 degree; differences within        5 degrees still can be acceptable.    -   n. determine direction of polarization; and    -   o. apply UV treatment 520

The lens' convex and concave mold can be made of transparent glass.About 5 cc of hard epoxy 517 is used, which should spread out to form alayer about 0.1 mm-0.5 mm thick, preferably 0.2 mm-0.3 mm for goodsurface tension. This eventually becomes layer of hard epoxy in lens.Epoxy liquid should be heated to about 80° C. to 90° C. so that theywill be liquid or semi-liquid, to help eliminate bubbles. The liquidepoxy is soft enough to flow, but it is not so viscous that it will flowaway without adhering. The liquid epoxy 517 can be dripped onto theconcave mold 518, smoothly expanding from the center in a circularmotion to evenly spread the epoxy 517 to help remove air bubbles. Thisprocess can be performed in an environment at approximately roomtemperature.

In one embodiment, holding frame holding retarder film 516 in contactwith convex mold 521, and the convex mold 521-plus-retarder film 516combination is inverted and placed on top of concave mold 518 andattached together. Because the final layer of hard epoxy 517 is lessthan 0.5 mm, no gasket is needed. During UV treatment 520, the liquidepoxy 517 is cured and made hard using ultraviolet light, heat,radiation, pressure, passage of time, or other methods for treatmentepoxy.

FIG. 7A depicts one embodiment of an overview of 3D Stereoscopic viewlens comprising a convex mold 721, a concave mold 726, lens substratelayer 724 and glass lens 725, retarder film 716, linear polarized film715. Depicted in FIG. 7B (from the left column down and up and throughthe right column), the steps are as follows:

-   -   a. polish and clean the surface of concave mold 726;    -   b. add about 5 cc of glass substrate 725 onto concave mold 726,        which creates the convex side of the lens; and    -   c. position concave mold 726 and convex mold 721 together so        that the outer surface of retarder film 716 can be pressed down        onto glass layer 725;    -   d. affix retarder 716 to convex mold 721;    -   e. apply glue 719 to the glass substrate layer 725    -   f. compress molds together;    -   g. determine direction of the retarder 716; and    -   h. dried with air or UV light 720;    -   i. affix linear polarized film 715 on the convex mold 721;    -   j. add UV glue 719 on the concave side of the retarder 716;    -   k. compress molds together; when laminating the retarder 716 and        linear polarized film 715, paying careful attention that the        angle is correct at +45 degrees and −45 degrees, but not limited        to any other combination of desired degree.    -   l. determine direction of polarization; and    -   m. dried with air or UV light 720    -   n. remove convex mold 721 from concave mold 726    -   o. add lens substrate (AC, CR, PU, TAC, or GLASS) 724 to convex        mold 721 and compress molds together to form a 3-D stereoscopic        viewing lens.

The retarder-plus-glass collection is then sent to an assembly line withUV treatment equipment to be hardened for about three minutes. Fineshaping can also be performed manually at this stage by cutting awayexcess retarder. This produces a retarder film with a hard layer ofglass on its outer, convex surface. In another embodiment, this producesa polarized wafer coated with glass on both sides. The uncoated concaveside, the glass-lined convex side, or both sides could then be combinedwith a base material, through casting in a gasket mold, injectionmolding, or other methods for combining lens components.

Lens substrate can be GLASS, acrylic (AC), polyurethane (PU), triacetate(TAC), casting resin (CR), cellulose acetate (CAB), cellulose propionate(CP), or NYLON; substrate can have one side or two sides' coatings.Linear polarized film also includes partially circular polarized film.

FIG. 8 depicts the combinations of lens inserts to right side and leftside depending on the direction of TV and projector. Although thepresent invention has been described by way of example with referencesto the drawings, it is to be noted herein that various changes andmodifications, including performing steps in different orders, will beapparent to those skilled in the art. Therefore, unless such changes andmodifications depart from the scope of the present invention, theyshould be construed as being included therein.

Example Three I. Utilizing PVA Film and Linear Polarized Film for LCDUse

FIG. 9A depicts one embodiment of an overview of utilizing PVA film asretarder film, using the methods depicted above, for LCD use comprisinga convex mold 921, a concave mold 926, lens substrate layer 924 andglass lens 925, ITO layer 928, LCD layer 927, retarder film 915.Depicted in FIG. 9B, the steps are as follows:

-   -   a. add lens substrate 925 onto the exposed, concave 926 (top        flat) side of the mold;    -   b. vacuum coated with ITO (electrode conductor) 928 to form the        direction in LCD;    -   c. add liquid crystal display layer (LCD) 927 to concave mold        926;    -   d. place convex mold 921 on top; having a lens substrate layer        916 adjoined with UV glue 919 to retarder film 924 so that the        concave 926 having LCD 927 surface presses against retarder film        924; by paying careful attention that the angle is correct at        +45 degrees and −45 degrees;    -   e. Applying UV treatment.

The same method can be applied on flat surface as depicts in FIG. 10

-   -   a. add lens substrate 1025 onto the exposed, bottom flat 1026        side of the mold;    -   b. vacuum coated with ITO (electrode conductor) 1028 to form the        direction in LCD 1027;    -   c. add liquid crystal display (LCD) 1027 to bottom flat mold        1026;    -   d. affixing retarder 1016 with substrate 1024 with glue 1019 to        top flat 1024;    -   e. place top flat 1021 on top; having a lens substrate layer        1024 adjoined with UV glue 1019 to retarder film 1016 so that        the bottom flat 1026 having LCD 1027 surface presses against        retarder film 1016; by paying careful attention that the angle        is correct at +45 degrees and −45 degrees;    -   f. apply UV treatment.

1. A curved retarder for a 3-D stereoscopic viewing lens wherein saidretarder film is comprised of a PVA film wherein said retarder film ismade comprising the following steps: a. mounting a PVA film to anassembly line; b. wetting, cleaning, and washing said PVA film throughsaid assembly line; c. softening, expanding and stretching said PVAfilm's x-axis through said assembly line; d. adding gap filling agent tosaid PVA film; e. stretching said PVA film's y-axis through a widthframe holder having an upper frame and a lower frame wherein said upperframe closes onto said lower frame whereby securing said PVA filmwherein said width frame holder extends along y-axis of said PVA filmwhereby transforming said PVA film into a retarder film; f. mountingsaid retarder film onto a multiple holding frame wherein said multipleholding frame is comprised of an upper frame and a lower frame whereinsaid upper frame closes onto said lower frame whereby securing said PVAfilm from shrinking; g. pressing a convex mold onto said retarder filmto force said retarder film into a desired curved shape through one ormore openings of said multiple holding frame; h. heating said retarderfilm to reduce said retarder film's moisture content; i. drying saidretarder film.